BASIC MECHANICAL ENGG.

MANUFACTURING PROCESSESWHAT IS MANUFACTURING? It is the process of converting raw material into finished product by using machine. Classification of Manufacturing process: 1. Casting 2. Metal forming/Deformation 3. Machining/Metal Cutting Process. 4. Surface finishing 5. Powder metallurgy 6. Sheet metal working 7. Metal Joining process 8. Process effecting change in properties.CASTING PROCESS In casting, Molten metal like cast iron, copper, aluminum is poured into mould of desired shape. After that allowing the molten metal to cool and solidify in the mould. Applications of casting:  Cylinder blocks, piston, clutch housing, gear blank  Jet engine blades, gear box housing  Machine tool beds, frames, gears  Water supply pipes, sanitary fittingsTYPES OF CASTING PROCESSES Sand casting – In this process castings are made using sand mould.SPECIAL TYPE OF CASTING PROCESS Permanent Mould Casting Process – there is metallic mould, so we can use no. of times (25000 times) This is also known as gravity die castingDIE CASTING PROCESS Making of casting by injecting the molten metal under high pressure into mould. This is also known as pressure die castingMETAL FORMING PROCESS Component of desired shape and size obtained through the plastic deformation of metal under action of externally applied force. Forging Process: First metal is heated and then plastically deformed to desired size under compressive force.CLASSIFICATION OF FORGING BASED ONTYPES OF DIES Open die forging process:  Closed Dies ForgingCLASSIFICATION BASED ON MODE OFAPPLICATION OF COMPRESSIVE FORCE Hand forging:DROP FORGING It is the process of deforming the hot material into desired shape by raising the die with the help of pneumatic cylinder and allowing it to fall so as to impart blow on materialPRESS FORGING It is the process of deforming the hot material into desired shape by raising the die with the help of pneumatic cylinder and allowing it to fall so as to impart blow on materialUPSET FORGING Upset forging is operated in horizontal directionSHEET METAL WORKING (PRESS WORKING) Process of manufacturing the components from the sheet metal. Thickness of the sheet metal ranging from 0.1 mm to about 6-8 mm. Types of sheet metal working:  Sheet metal cutting process  Sheet metal forming processSHEET METAL CUTTING PROCESS Piercing : Producing a hole of any desired shape in a sheet metal by using punch and die.

 Punching : Producing a circular hole in a sheet metal by

using punch and die.SHEET METAL CUTTING PROCESS Blanking: operation of cutting out a piece of the required shape from the sheet metal.

 Perforating: operation of producing a number of evenly

spaced holes in a metal sheet.SHEET METAL CUTTING PROCESS Slitting: operation of cutting sheet metal in straight line along the length.

 Lancing: operation of cutting a part of sheet metal through

some portion of its length and then bending the cut portionSHEET METAL CUTTING PROCESS Notching: operation of removal of small part of metal sheet of desired shape from the edge of metal sheet.SHEET METAL FORMING PROCESS Drawing: process of forming a flat metal sheet into 3 dimensional hollow shape by means of punch that causes the metal to flow into the die cavity.SHEET METAL FORMING PROCESS Deep Drawing: If the depth of the formed cup exceeds the diameter of formed cup.SHEET METAL FORMING PROCESS Bending: It is the process by which a straight length metal sheet is transformed into curved length

 U- Bending: It is the process by which a straight length metal sheet is

transformed into U shape.SHEET METAL FORMING PROCESS Curling: an edge of a circular cross section is formed along the sheet or at the end of tube.SHEET METAL FORMING PROCESS Forming: Process of shaping a flat metal sheet into a surface of desired profile.SHEET METAL FORMING PROCESS Coining: Process of cold squeezing of metal in which aal the surfaces are confined within the set of dies.

 Embossing: Process of producing the depressed or raised

impression of letters, figures, or designs on metal sheet.SHEET METAL FORMING PROCESS Wire Drawing: It is cold working process of producing the wire from the rod through the successive reduction of the diameter.METAL JOINING PROCESS Welding: process of joining two metallic parts together by heating them to a plastic state or semi molten state, with or without application of pressure and with or without a filler material. Types of welding Process:  Pressure welding (Plastic welding)  Non-pressure welding (Fusion welding)PRESSURE WELDING PROCESS Forge Welding:  Electrical resistance Welding:PRESSURE WELDING PROCESS Seam Welding:NON - PRESSURE WELDING PROCESS Electric arc Welding:TYPES OF ELECTRIC ARC WELDING Shielded Metal Arc Welding (SMAW)TYPES OF ELECTRIC ARC WELDING Tungsten Inert Gas Welding (TIG Welding)TYPES OF ELECTRIC ARC WELDING Metal Inert Gas Welding (MIG Welding)TYPES OF ELECTRIC ARC WELDING Gas WeldingBRAZING Brazing: It is the process of joining 2 workpiece, made of similar or dissimilar materials by heating them to a specified temperature above 450° C but below melting temp. of workpiece.SOLDERING Soldering: It is the process of joining 2 workpiece, made of similar or dissimilar materials by heating them to a specified temperature below 450° C.